Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
  • C04B20/10—Coating or impregnating
  • C04B20/1018—Coating or impregnating with organic materials
  • C04B20/1029—Macromolecular compounds
  • C04B20/1033—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
  • B09B—DISPOSAL OF SOLID WASTE
  • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
  • B09B3/20—Agglomeration, binding or encapsulation of solid waste
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
  • B09B—DISPOSAL OF SOLID WASTE
  • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
  • B09B3/20—Agglomeration, binding or encapsulation of solid waste
  • B09B3/21—Agglomeration, binding or encapsulation of solid waste using organic binders or matrix
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
  • B09B—DISPOSAL OF SOLID WASTE
  • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
  • B09B3/20—Agglomeration, binding or encapsulation of solid waste
  • B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds
  • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B26/06—Acrylates
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

• the present invention relates to methods of manufacturing articles.
• the present invention seeks to address these problems by providing an energy efficient method for manufacturing building materials from reclaimed aggregates and waste products.
• the invention in a first aspect, relates to a method of producing a composite article comprising the steps of obtaining material in fibre or particulate form, coating fibres or particles of the material with a binder, and pressing at least a portion of the material in a mould to form an article.
• the material comprises waste product such as any material selected from organic or inorganic wastes or by-products of other processes.
• the material may comprise any material that is generally considered to be waste.
• the material comprises material selected from the group comprising : mineral, cement block, bagasse, paper, sterilised municipal waste, glass. More preferably, the waste product comprises a mineral material such as slate, mica, granite, sands, marble, dolomite, flint, basalt, slag, bauxite, calcite or andulucite.
• a mineral material such as slate, mica, granite, sands, marble, dolomite, flint, basalt, slag, bauxite, calcite or andulucite.
• the method may produce, for example, a tile or brick which is tough and strong and takes on the aesthetic characteristics of the waste material from which it is made.
• a dye might be used to provide a tough and strong article having a substantially uniform colour.
• the particles of material have a size distribution between 20 ⁇ m and 2000 ⁇ m. More preferably, the material has a size distribution of between 520 ⁇ m and 2000 ⁇ m.
• the material may be milled and/or sized to control the size distribution accordingly. In certain embodiments, it is desirable to separate the material into a number of size ranges which may then be homogeneously mixed together.
• the material comprises, at least in part, material reclaimed from the waste product of the method of the present invention. In other embodiments, the material comprises, at least in part, material milled from articles formed according to the method of the present invention.
• the material has a moisture content of 2% or lower. If the material has a moisture content of above 2%, it may be subjected to an auxiliary drying step, therein reducing the moisture content to 2% or lower.
• the binder comprises a water based polymer. More preferably, the binder comprises an acrylic polymer. Most preferably, the binder comprises a blend of acrylic polymers in aqueous solution or held in a water suspension.
• the coating step comprises mixing the material with the binder in a mixer.
• the mixer may comprise a continuous mixer or a batch mixer.
• the material and binder are preferably mixed for less than 20 minutes. More preferably, the material and binder are mixed for less than 10 minutes. If the material and binder are mixed continuously, they are mixed so as to have a Froude number less than 1.
• the coating step comprises mixing the waste material and the binder in a material : binder ratio of 65-95:35-5. More preferably, the coating step comprises mixing the material and the binder in a material: binder ratio of 90: 10.
• the method comprises a drying step following the coating step to dry coated material before pressing.
• the drying of the coated particles or fibres allows them to be stored in a condition ready for moulding.
• the coated particles have improved fluidic properties over wet particles or fibres. This quality provides far easier and more efficient processing.
• the drying step preferably comprises drying the coated material in a continuous dryer to produce dried coated material.
• the drying step comprises drying the coated material in a batch dryer.
• the drying step comprises exposing the coated material to a current of air at elevated temperature.
• the current of air is at a temperature of between about 100 0 C and about 200 0 C.
• the drying step has a duration of less than 20 minutes. More preferably, the drying step has a duration of less than 10 minutes. Preferably an aliquot of dried coated material is introduced to the coated material prior to the drying step.
• the drying step reduces the moisture content of the coated materialto 5% or lower. More preferably, the drying step reduces the moisture content of the coated material to 3% or lower. Most preferably, the drying step reduces the moisture content of the coated material to 2% or lower.
• the step of pressing the material comprises introducing a first aliquot of the coated material to a mould.
• the first aliquot of coated material is smoothed within the mould to create a first layer of coated material.
• the mould may be of plain or textured pattern.
• a textured pattern mould may be used when it is desirable to provide an article with a patterned surface, such as for decorative or non-slip applications.
• reinforcing agents are introduced to the mould.
• the reinforcing agents comprise materials selected from the group: metal, plastic, glass, natural or synthetic materials in the form of rods, fibres, meshes and/or lattices.
• the reinforcing agents are introduced to the mould atop the first layer of coated waste material.
• a second aliquot of the coated material is introduced to the mould.
• the second aliquot is introduced to the mould atop the first layer of coated material or atop the reinforcing agents.
• the second aliquot of coated material is preferably smoothed within the mould to create a second layer of coated material.
• the step of pressing the material comprises applying a pressure of between lOOkgcm "2 and 200kgcm "2 to the material. It is desirable for the pressing to be performed by a pressing machine. In preferred embodiments, the pressing machine is arranged to lock the mould shut at elevated pressure, such that pressing may continue after the mould is removed from the pressing machine.
• the step of pressing the material is performed at elevated temperature. More preferably the pressing step is performed at between 90 0 C and 250 0 C. Most preferably, the pressing step is performed at between 180 0 C and 220 0 C. This may be achieved by, for example, providing internal heaters in the mould.
• the material is at elevated temperature during the pressing step. More preferably, the material is at between 9O 0 C and 250 0 C during the pressing step. Most preferably, the material is at between 180 0 C and 22O 0 C during the pressing step.
• the material is pressed for less than 10 minutes. More preferably the material is pressed for between 30 seconds and 5 minutes.
• the article so-formed has a density between 200 kg/m 3 and 4000 kg/m 3 .
• a method of producing a composite article comprising obtaining first and second materials in fibre or particulate form, separately coating fibres or particles of the first material and the second material, layering particles of the first material and the second material within a mould, and pressing the layered first and second materials to form an article.
• the invention relates to a composite article manufactured according to a method as described above.
• Figure 1 displays a schematic process diagram of a process including the method of the invention.
• Figure 2 displays a first aliquot of waste material in a mould.
• Figure 3 displays a first layer of waste material in a mould.
• Figure 4 displays a reinforcing agent resting atop a first layer of waste material in a mould.
• Figure 5 displays a second aliquot of waste material in a mould.
• Figure 6 displays a second layer of waste material in a mould ready for pressing.
• Figure 7 displays waste material being pressed within a mould.
• Figure 8 displays a bi-layered article made according a process including a method of the invention.
• the invention relates to a method of making tiles, in particular roof tiles, from waste materials. It is envisaged, for example that the method be used to manufacture high quality tiles from waste aggregate materials such as dust, slag or granules of such materials as slate, mica, granite, marble, andulucite, sands, cement block waste, sterilised municipal waste, bagasse, waste paper and sludge.
• waste aggregate materials such as dust, slag or granules of such materials as slate, mica, granite, marble, andulucite, sands, cement block waste, sterilised municipal waste, bagasse, waste paper and sludge.
• waste material is provided and transferred via a material transfer unit 14 to a pre-sieve hopper 16.
• the waste material is introduced to sieve 18 to be sized, such that a particle size distribution of between 20 ⁇ m and 2000 ⁇ m is collected in a collection hopper 20.
• Particles of waste material found to be too large for the preferred particle size distribution may be transferred to a mill (not shown) to be milled and reintroduced to pre-sieve hopper 16, thereby maximising the use of available material.
• the particles of waste material do not comprise more than about 2% moisture at this stage of the process. If the moisture content is found to be too high, then the waste material is dried by an auxiliary belt drier 21.
• the sized waste material is transferred from the collection hopper 20 to a storage hopper 22, which gravimetrically feeds the sized waste material into a continuous mixer 24.
• An accurate pumping system 26 provides a water based, acrylic polymer binder to the mixer 24, such that the ratio of waste material to binder is 90: 10 by weight.
• the mixer 24 is operated to effect a thorough coating of the waste product particles. This is achieved by ensuring that the mixing has a Froude number less than 1.
• the mixer 24 effects mixing for a period of between 4 minutes and 10 minutes, during which time the particles of waste material are evenly coated with the binder.
• the particles of waste material are introduced to a belt dryer 28, where they are exposed to a current of air, preferably at a temperature between 150 0 C and 200 0 C for between 1 and 10 minutes.
• the drying step may be optimised by the introduction of a quantity of fully dried coated waste material to the wet coated waste material before the step commences. After the drying step, the coated waste material is has a moisture content of around 2% to 3%.
• the dryer transfers the dried coated waste product to a mould filling hopper 30, from where aliquots of the product are introduced to moulds 32 by a mould filling device 34.
• This is preferably achieved by adding a first aliquot 38 of dried coated waste material to a mould 32, as shown in Figure 2, then smoothing the first aliquot 38 of waste material to create a first layer 40, as shown in Figure
• Optional reinforcing materials 42 such as metal or plastic rods, or glass, natural or synthetic fibres, or meshes or lattices, may be introduced to the mould.
• a second aliquot 44 of the dried coated waste product is then introduced to the mould 32, as shown in
• the finished tile is removed from the mould and allowed to cool.
• the dryer is preferably a belt dryer, or some other such dryer that allows for continuous drying, but in other embodiments the dryer may be a drum dryer, or some other dryer suitable for batch drying.
• the mixing step and drying step are performed within the same apparatus, in a substantially simultaneous manner.
• the quantity of sized waste material and binder introduced to the mixer is measured volumetrically.
• a bi-layered composite article 48 is formed.
• a second waste product is coated and dried in a separate process line, by a method substantially as described above, eventually being collected in a second mould filling hopper 30.
• first layer of dried coated waste product and the optional reinforcing agents have been introduced to the mould 32, as described above, an aliquot of the second dried coated waste product is introduced atop the first layer and smoothed to make a second layer.
• the first ,and second waste products are then pressed together, as described above, to make a bi-layered article.
• the bi-layered article created has two major surfaces, each having a characteristic appearance, dependent largely on the visual and textural qualities of the two waste materials used.
• Such a bi-layered article affords an additional level of choice to the end-user. For example, if the product is a tile, then the user may lay an array of tiles in a chequered pattern, without exhausting his or her supply of tiles of one of the colours.
• a bi-layered article, as described above, could also be manufactured by using two aliquots of a single waste product, coated and dried substantially as described above, with one or both of the two layers having a pigment or dye introduced in the coating or drying step. Additionally, or alternatively, each of the major surfaces of the bi-layered product may have a different finish applied to it in a final step of manufacture.
• certain inclusions may be made in the mixture such that the finished article exhibits secondary functionality.
• metallic elements may be included to enable a tile to discharge static electricity, so enabling it to be used in electrically sensitive locations. Such metallic elements could also be heated to provide a source of heating for the area of use.
• the composite material made by the method described above exhibits exceptional qualities of, for example, dimensional stability throughout exposure to the water and extremes of temperature.
• the composite material is thus suitable for many applications beyond tiles, including bricks, lintels and decorative or bespoke construction mouldings.
• the composite material exhibits excellent wear characteristics when tested for deep abrasion properties.
• a tile was manufactured according to the method described above. The tile was then tested according to the appropriate ISO standards, unexpectedly yielding excellent results. The results of these tests are shown below.
• Breaking strength Not less than 750N (ISO 10545 - 4) Deep abrasion resistance: Not more than 124mm 3 (ISO 10545-6)
• End of life tiles made according to the present invention were milled to a suitable particle size and used as at least part of a starting material for use in the method. No deleterious properties of the so-formed article were identified.
• Tiles at the end of their useful life can also be used as a filler for other uses.

Landscapes

• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Environmental & Geological Engineering (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Mechanical Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Processing Of Solid Wastes (AREA)
• Reinforced Plastic Materials (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)

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• 2007
  • 2007-10-25 GB GB0720958A patent/GB2454169A/en not_active Withdrawn
• 2008
  • 2008-10-24 WO PCT/GB2008/003630 patent/WO2009053720A2/en active Application Filing
  • 2008-10-24 EP EP08842638A patent/EP2225053A2/de not_active Withdrawn

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